Servicing

Instructions

Heatranger 440/460/480/499KB

For use in GB and IE

DESN 511653 B

REMEMBER, when replacing a part on this appliance, use only spare parts that you can be assured conform to the safety
and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly
authorised by AGA.

PLEASE READ THESE INSTRUCTIONS BEFORE SERVICING THIS APPLIANCE

raywarranty@aga-web.co.uk

05/14 EINS 511642-E

SECTION

Contents

CONTENTS

CONSUMER PROTECTION
HEALTH & SAFETY

PAGE
4
4

INTRODUCTION
SERVICE SCHEDULE

5
5

BURNER REMOVAL

PREPARATION
BURNER ACCESS
BURNER REMOVAL

6
6
7

CLEANING

HEAT EXCHANGER CLEANING

OVEN AND HOTPLATE FLUEWAY CLEANING

8-10
10

BURNER SERVICING

INTRODUCTION
BURNER NOZZLE REMOVAL
BURNER NOZZLE REPLACEMENT
PHOTO ELECTRIC CELL (PEC) CLEANING
FAN CLEANING
RE-ASSEMBLE BURNER

11
12
12
13
13
13

OIL PUMP SERVICING

INTRODUCTION
OIL PUMP STRAINER CLEANING
OIL LINE FILTER CLEANING

14
14
14

RE-COMMISSIONING

BLEED AIR FROM OIL SUPPLY

FIT PRESSURE GAUGE
VENT OIL PUMP
ADJUST OIL PRESSURE
SET COMBUSTION AIR
CHECK SMOKE

15
15
15
15
16
16

REPLACEMENT OF PARTS - FAN MOTOR

(BURNER)
IGNITION ELECTRODES
IGNITOR
RELAY
SOLENOID COIL
CONTROL BOX
PEC
PUMP ACCESS

17
17
18
18
18
19
19
20

REPLACEMENT OF PARTS - ELECTRICAL COMPONENT ACCESS

ELECTRICAL CONTROLS
TO FIT NEW BOILER CONTROL THERMOSTAT
TO FIT NEW BOILER PUMP OVERRUN THERMOSTAT
TO FIT NEW COOKER SAFETY OVERHEAT THERMOSTAT
TO FIT NEW BOILER SAFETY OVERHEAT THERMOSTAT
TO FIT NEW OVEN CONTROL THERMOSTAT
TO FIT NEW PROGRAMMER
TO FIT NEW SELECTOR SWITCH
RE-ASSEMBLE

21-22
23
23
24
25
25
26
26
27

REPLACEMENT OF PARTS - VENT FAN

(VENT FAN)
VENT FAN SWITCH

28
28

ELECTRICAL CONTROLS

PUMP OVERRUN FACILITY

OVERHEAT SAFETY THERMOSTATS
CONTROL CIRCUIT - EXTERNAL
CONTROL CIRCUIT - BOILER
CONTROL CIRCUIT - COOKER

29
29
30
31
32

Contents

SECTION

CONTENTS

PAGE

FAULT FINDING

WIRING DIAGRAM - APPLIANCE

BURNER DOES NOT START
INFORMATION SYSTEM COOKER BURNER
(COOKER BURNER TYPE DKO 970)
INFORMATION SYSTEM COOKER BURNER
(COOKER BURNER TYPE DKO 970N)
FAULT FINDING - BOILER
FAULT FINDING - COOKER
HIGH SMOKE NUMBERS/OIL SMELLS

33
34
35-36

37-38
39-40
41-42
43

Consumer Protection
As responsible manufacturers we take care to make sure that our products are designed and
constructed to meet the required safety standards when properly installed and used.
IMPORTANT NOTICE: PLEASE READ THE ACCOMPANYING WARRANTY
Any alteration that is not approved by AGA could invalidate the approval of the appliance,
operation of the warranty and could affect your statutory rights.

Health & Safety

This appliance may contain some of the materials that are indicated. It is the Users/Installers
responsibility to ensure that the necessary personal protective clothing is worn when handling
where applicable, the pertinent parts that contain any of the listed materials that could be
interpreted as being injurious to health and safety, see below for information.
Firebricks, Fuel beds, Artificial Fuels
When handling use disposable gloves.
Fire cement
When handling use disposable gloves.
Glues and Sealants
Exercise caution - if these are still in liquid form use face mask and disposable gloves.
Glass Yarn, Mineral Wool, Insulation Pads, Ceramic Fibre
May be harmful if inhaled. May be irritating to skin, eyes , nose and throat. When handling avoid
contact with skin or eyes. Use disposable gloves, face-masks and eye protection. After handling
wash hands and other exposed parts. When disposing of the product, reduce dust with water
spray, ensure that parts are securely wrapped.
Kerosene & Gas Oil fuels (mineral oils)
1. The effect of mineral oils on the skin vary according to the duration of exposure.
2. The lighter fractions also remove the protective grease normally present on the surface of the
skin. This renders the skin dry, liable to crack and more prone to damage caused by cuts and
abrasions.
3. Oil acne is recognised by the presence of skin rashes. The arms are most often affected,
but may occur where there is contact with oil or oily clothing.
- Seek medical attention for any rash.
- Avoid skin contact with mineral oil or clothing contaminated with mineral oil.
4. Inhalation of mineral oil vapours must be avoided. Never fire the burner in the open as
unburnt oil vapours are likely to occur.
5. Use a suitable barrier cream which will give protection against mineral oil, lanolin based hand
creams are usually very effective.
6. Never syphon mineral oils by use of the mouth. If accidentally swallowed, call a doctor, do
not induce vomiting.
NOTE: SMOKE/SMELL EMITTED DURING INITIAL USAGE
Some parts of the cooker have been coated with a light covering of protective oil. During initial
operation of the cooker, this may cause smoke/smell to be emitted and is normal and not a fault
with the appliance, it is therefore advisable to open doors and or windows to allow for ventilation.
Lift the lids to prevent staining the linings.

INTRODUCTION

SERVICE SCHEDULE

To ensure the best performance from your Rayburn it

should be serviced once a year; preferably at the start of
the heating season.

Annual Service
During annual service flexible oil line, burner nozzles and
burner head seals MUST BE CHANGED.

This appliance must be commissioned by a competent

engineer, such as OFTEC approved or a commissioning
engineer as shown on the Rayburn list.

WIRING: Ensure there is no damage or loose

connections. This should be carried out by a competent
engineer.

Failure to install and maintain appliances correctly could

lead to prosecution.

BURNER REMOVAL - for cleaning and inspection.

CLEANING - Boiler heat exchanger flueways, oven and
hotplate flueways together with ceramic fibre burner
chambers.
BURNER SERVICING.
OIL PUMP SERVICING - Cleaning of fuel line strainer.
RE-COMMISSIONING.
REPLACEMENT PARTS.

An additional flueway and combustion chamber clean

halfway through the heating season may be necessary in
some cases.
The Rayburn cannot be serviced whilst hot, so both oven
and boiler thermostats should be turned off on the
evening before the service visit.

Oven Door Fit - Both doors must be checked and adjusted

if necessary to ensure the alignment with the door catch
is correct, the keep is secure and the oven is sealed when
the door is closed.
Additional Flueway Clean
It may be necessary in some installations to give the
boiler flueways a clean out at the end of the heating
season.
Balanced Flue Terminal
Check terminal housing for ingress of foreign matter - dust
leaves etc.
Check terminal area is clear of any obstructions which
would hinder the dispersal of the products of combustion
and clean air entry.
If necessary remove Terminal Housing, for cleaning of
ducts and airways, and ensure that all sealed joints are
remade on re-assembly. Replace terminal guard.

Burner Removal
PREPARATION
WARNING: BEFORE REMOVING SERVICE ACCESS
COVERS OR THE OIL BURNERS ENSURE THAT ALL
ELECTRICAL SUPPLIES TO THE APPLIANCE HAVE
BEEN ISOLATED
The burners can be removed without disconnecting the oil
supply pipe. However if the filters are being cleaned or a
pressure gauge fitted to the pump then the oil supply
should be turned OFF and arrangements made to catch
any oil which will leak from the oil pump.

BURNER ACCESS
SEE FIG. 1
1. Open up the bottom burner access door. Remove
door and put in a safe place.
2. Remove the 4 inner panel securing screws and
remove panel.
3. Remove the 3 plinth securing screws and remove
plinth.
Fig. 1

DESN 511998

Burner Removal
BURNER REMOVAL
IMPORTANT: DURING BURNER REMOVAL CARE
MUST BE TAKEN NOT TO DAMAGE THE CERAMIC
FIBRE INSULATION.
SEE FIG. 2, 3 & 4
1. Place a sheet on the floor in front of the cooker to act
as a working area.
2. Disconnect the 4-pin plug at the side of the burner.
3. Disconnect air intake.

Fig. 2

DISCONNECT 4-PIN
PLUG

DESN 511999

HEAD RETAINING
BRACKET

SEE FIG. 3

CENTRE
LOCKING NUT

4. Undo the central locking nut and remove head

retaining bar.
5. Undo burner mounting plate.

BURNER
LOCKING
NUT

Fig. 3

DESN 512007

SEE FIG. 4
6. Withdraw the burner unit.
7. To remove the burner unit completely, it maybe
necessary to disconnect the air intake hose from the
burner unit.

Fig. 4

DISCONNECT
AIR INTAKE

DESN 512006 A

Cleaning
HEAT EXCHANGER CLEANING
IMPORTANT: DURING CLEANING CARE MUST BE
TAKEN NOT TO DAMAGE THE CERAMIC FIBRE
INSULATION.
SEE FIG. 5
1. Lift insulation covers and remove hotplate using
lifting hooks provided.

Fig. 5

DESN 510523

Fig. 6

DESN 512011

SEE FIG. 6
2. Remove the 4 flue cleaning access door securing
bolts and remove door.
3. Using the rods provided remove the boiler flueway
baffles from between the boiler cross waterways.

The baffles are assembled in alternate directions to allow

the gases to flow front to back through the assembly.
Each heat exchanger has two rows of baffles.
Ensure that the baffles are having the top and bottom
plates of the same width and marked TOP are fitted last.
One at top each flueway.
Total number of baffles fitted are:440
460
480
499

=
=
=
=

6
6
8
10

(2
(2
(2
(2

x
x
x
x

3)
3)
4)
5)

Cleaning

Fig. 6A

Cleaning
SEE FIG. 7
4. Lift top plate enamelled cover panel (behind LH
insulating cover) remove insulation pad and sealing
plate.
5. Clean the boiler outlet flueway by inserting the flexible
brush through the top plate aperture, directing it
towards the flue outlet. Scrape the deposits towards
the heat exchanger.
6. Thoroughly clean boiler heat exchanger flueway.
7. Carefully vacuum any debris that has fallen down into
the burner chamber.
8. Clean and replace boiler flueway baffles in reverse
order. Locate boiler flue access door, secure.
9. Replace sealing plate, insulation pad and cover panel.

COVER
PANEL

INSULATION
PAD

Fig. 7

DESN 511652

Fig. 8

DESN 511590

OVEN & HOTPLATE FLUEWAY

CLEANING

SEE FIG. 8

1. Remove the top oven door and place in a safe

position.
2. Remove side and base access doors use hex. driver.
3. Thoroughly clean top, side and base flueways through
access apertures with brush.
4. Remove all debris with vacuum cleaner.
5. Replace side and base access doors. Secure in
position using hex. driver.
6. Brush and clean in between hotplate ribs on
underside.
7. Examine soft rope seal located around hotplate
aperture in top plate and two rope seals on hotspot.
Replace if frayed or damaged.
8. Replace hotplate ensuring the underside ribs lie over
the oven, and that it seals the top plate.

10

Burner Servicing
INTRODUCTION

BOILER

SEE FIG. 9, 10A, 10B & 10C

8 VANES

It is recommended that each side of the burner is serviced

individually so as not to get the components from the two
burners mixed up.
The correct combination of burner blast tubes and
diffusers are shown.
To remove blast tube, slacken grub screws and pull
forwards.

COOKER
10 VANES

Fig. 10A

440/460KB

BOILER
10 VANES
3mm HOLES
SMALL SLOTS

Fig. 9

COOKER
10 VANES

Fig. 10B

480KB

BOILER
10 VANES
5mm HOLES
LARGE SLOTS

COOKER
10 VANES

11

Fig. 10C

499 KB

Burner Servicing
BURNER NOZZLE REMOVAL
SEE FIG. 11
Disconnect ignition leads
Remove two socket head screws.
Remove head assembly complete.
Remove ignitor assembly, by removing countersunk
screw and clamp.
5. Unscrew nozzle from its holder with a correctly fitting
tubular spanner to avoid damage to hexagon.
1.
2.
3.
4.

Fig. 11

BURNER NOZZLE REPLACEMENT

DESN 512004

3mm

SEE FIG. 12
1. Replace nozzle by a new one of the same make and
specification.
MODEL
440KB
460KB
480KB
499KB

COOKER

NOZZLE
TYPE

BOM
CODE

BOILER

NOZZLE
TYPE

BOM
CODE

0.35 @
80 S

RO4M
998940

0.35 @
60 H

RO4M
998939

0.40 @
80 EH

RO4M
998391

0.65 @
80 EH

RO4M
998394

0.40 @
80 EH

0.40 @
80 EH

RO4M
998391

RO4M
998391

0.55 @
80 EH

0.85 @
80 EH

RO4M
998392

Fig. 12

RO4M
998395

2. Ensure that mating faces are clean.

3. Hold nozzle holder with correct spanner when
tightening nozzle.
4. Typically finger tight plus 1/4 turn with spanner is
sufficient.
DO NOT OVERTIGHTEN.
5. Ensure electrode gaps are correct.

12

DESN 510538

Burner Servicing

PHOTO ELECTRIC CELL (PEC)

CLEANING

SEE FIG. 13

Withdraw Photo Electric Cell from the burner head. Clean

PEC sensing end with a soft cloth taking care not to
scratch the light sensitive body. Re-insert PEC taking care
to insert the correct way round.
Should the cell show signs of distortion or cracking,
replacement will be necessary. See PEC replacement,
page 19.

Fig. 13

FAN CLEANING

DESN 512003

440KB & 460KB

440/460KB ONLY
1. Clean between the blades of the fan impellor with a
small brush and remove any residue.
The fan motor flange has 4 fixings to the fan case.
480/499KB ONLY
1. Remove 4 fixing screws and pull off fan case inlet.
2. Clean between the blades of the fan impellor with a
small brush and remove any residue.
Fig. 14

RE-ASSEMBLE BURNER

DESN 511996

480KB & 499KB

SEE FIG. 14 & 14A

Re-assemble the burner in reverse order.
NOTE: Burner head gaskets should be renewed at each
service.

13

FIG. 14A

DESN 515883

Oil Pump Servicing

INTRODUCTION
To carry out servicing on the oil pump. Turn off the oil line
isolating valve near to the appliance.
SEAL
STRAINER
COVER

OIL PUMP STRAINER CLEANING

SEE FIG. 15
1.
2.
3.
4.

Remove 4 socket head screws.

Remove filter.
Wash with clean petrol or paraffin.
Re-assemble filter in reverse order.

FUEL INLET

OIL LINE FILTER CLEANING

1. Turn OFF the line isolating valve fitted prior to the oil
line filter.
2. Follow manufacturers instructions to remove filter
element from the housing, taking care to collect
Kerosene residue from the filter housing.
3. Wash filter thoroughly in clean petrol or paraffin.
4. Re-assemble in reverse order.

Fig. 15

NOTE: Flexible fuel hose (s) must be replaced at each

service.

14

DESN 512002

Re-commissioning
BLEED AIR FROM OIL SUPPLY
SEE FIG. 17A

Disconnect the flexible oil pipe line at the pump inlet, open
the stop valve slowly and run off some of the oil into a
receptacle to establish an air free supply to the pump.
Remake the connection oil tight and leave valve open.

FIT PRESSURE GAUGE

SEE FIG. 16

Remove the bleed screw from the manifold and fit an oil
pressure gauge with R 1/8 connection to check the pump
output pressure.

SWITCH ON ELECTRICITY

Fig. 16

Set the boiler burner time clock to continuous and turn the
boiler thermostat to maximum. The boiler burner should
run on pre-purge for 7-15 seconds. With the ignition spark
energised. The oil solenoid valve should open allowing
the burner to fire.

RESET
BUTTONS

PRESSURE PORT/
BLEED SCREW

DESN 511999

Until all the air from the oil pump is flushed out there may
be some flame instability resulting in the burner locking
out. This will be shown by the burner stopping and the
illumination of the signal light in the reset button of the
control box (see Fig. 16). IN THIS EVENT, WAIT AT
LEAST ONE MINUTE, then press the re-set button to
restart.

VENT OIL PUMP

SEE FIG. 16
Whilst the burner is running, vent air from the pump by
slackening the pressure gauge port sufficient to allow air
to bleed air. When bubble free oil seeps out re-tighten.

Fig. 17

OIL PRESSURE
ADJUSTMENT

DESN 511997

ADJUST OIL PRESSURE

SEE FIG. 17

With the burner running check the oil pressure on the

pressure gauge.
If the pressure gauge is not indicating the correct reading
then adjust the pressure by turning the pressure regulator
clockwise to increase or anti-clockwise to decrease the
pressure until the pressure gauge reads 10 bar
(145Ibf/In2).
NOTE: 440KB ONLY
Increase/decrease pressure gauge until pressure reaches
8 bar (120Ibf/In2).

NOTE: 499KB ONLY

During initial start up, the pressure will indicate
approximately 100 psi for 30 seconds then up to 10 bar
(145Ibf/In). Any adjustments must be made after the
sequence has been completed.

OIL PRESSURE
ADJUSTMENT

15

Fig. 17A

DESN 512046

Re-commissioning
SET COMBUSTION AIR
SEE FIG. 18 & 18A
After 15 minutes of the boiler burner running.
Remove the enamelled top cover panel and the insulation
pad.
Remove the plugging screw and insert the sensing end of
a portable indicator to check the CO2 (Carbon Dioxide)
level. Adjust the boiler burner air intake until a reading of
11/11.5% CO2 is recorded on the indicator.

CHECK SMOKE
SEE FIG. 18A
Remove the CO2 sampling tube and using the same hole
for flue sampling insert the sensing end of a Baccarach
Smoke Pump and check that the smoke in the boiler flue
ways does not exceed No.2 on the scale.
Replace the plugging screw, insulation pad and cover
panel.
Switch off the boiler burner.
COOKER BURNER - SEE FIG. 18 A

Fig. 18

Switch on cooker burner

After 15 minutes of the cooker burner running.
Repeat the above procedures for the cooker burner. To
sample the flue gases from the cooker burner lift up the
R.H. insulating cover and remove the countersunk
headed screw in the hotplate. The cooker burner should
be set to 11.0/11.5% CO2 with a maximum Smoke No. of
2.

BOILER BURNER
FLUE GAS SAMPLING
HOLE

Replace the countersunk headed screw on completion

ensuring that it will not interfere with any pots and pans
placed on the hotplate.

16

Fig. 18A

DESN 512001

COOKER BURNER
FLUE GAS SAMPLING
HOLE

DESN 511652

Replacement of parts (Burner)

FAN MOTOR

440/460KB ONLY

SEE FIG. 19 & 19A

Follow instructions in sections BURNER ACCESS, Steps
1 to 3 and BURNER REMOVAL, Steps 1 to 6.
Remove 3-pin plug.
Remove solenoid plug (499KB ONLY).
Disconnect oil pipe.
Remove four socket head screws. Lift off motor.
NOTE: 440K ONLY - Remove 4 screws and withdraw
motor.
5. Remove grub screw, slide off fan. Re-assemble in
reverse order.
1.
2.
3.
4.

NOTE: Ensure that gaskets and seals are in place and in

good condition.

Fig. 19

DESN 511996

480/499KB ONLY

IGNITION ELECTRODES
Follow instructions in BURNER ACCESS, Steps 1 to 3
and BURNER NOZZLE REMOVAL, Steps 1 to 5.
SEE FIG. 20
Disconnect ignition leads.
Remove 2 socket head screws.
Remove head assembly complete.
Remove ignitor assembly, by removing countersunk
screw and clamp.
5. Fit new ignition electrode assembly, re-assemble in
reverse order.
6. Check electrode gap and reset if necessary.
1.
2.
3.
4.

17

Fig. 19A

DESN 515884

Fig. 20

DESN 512004

Replacement of parts (Burner)

IGNITOR
REMOVE EARTH
SCREW

SEE FIG. 21
Follow instructions in sections BURNER ACCESS, Steps
1 to 3, BURNER REMOVAL, Step 4.
1.
2.
3.
4.
5.
6.

Remove both HT leads from ignitor.

Remove mains plug from ignitor.
Remove earth screw.
Remove 2 ignitor securing screws.
Remove ignitor.
Fit new ignitor, re-assemble in reverse order.

Fig. 21

DESN 511994

Fig. 22

DESN 511991

Fig. 23

DESN 511993

RELAY
SEE FIG. 22
Follow instructions in sections BURNER ACCESS, Steps
1 to 3, BURNER REMOVAL Steps 1 to 6.
1. Remove push on connectors (noting position of each
connector).
2. Remove two relay fixing screws.
3. Fit relay, re-assemble.

SOLENOID COIL
SEE FIG. 23
Follow instructions in sections BURNER ACCESS, Steps
1 to 3, BURNER REMOVAL, Steps 1 to 5.
1.
2.
3.
4.
5.

Slacken solenoid plug securing screw.

Remove plug.
Remove solenoid securing nut and washer.
Remove solenoid coil.
Fit new solenoid coil, re-assemble in reverse order.

18

Replacement of parts (Burner)

CONTROL BOX
SEE FIG. 24
Follow instructions in section BURNER ACCESS. Steps 1
to 3.
1. Undo central fixing screw.
2. Gently pull control box away from base.
3. Fit new control box, re-assemble in reverse order.

Fig. 24

DESN 511992

fig. 25

DESN 512003

PEC
SEE FIG. 25
Follow instructions in section BURNER ACCESS, Steps 1
to 3.
1.
2.
3.
4.

Withdraw P.E.C. from burner head.

Push in retaining clip and slide P.E.C. out.
Fit new P.E.C.
Re-insert P.E.C., taking care to insert the correct way
round.

19

Replacement of parts (Burner)

PUMP ACCESS
SEE FIG. 26

PUMP FIXING
SCREWS (3)

Follow instructions in sections BURNER ACCESS, Steps

1 to 3 and BURNER REMOVAL, Steps 1 to 5.
1. Isolate fuel supply.
2. Disconnect flexible hose. (This
annually)
3. Remove solenoid plug.
4. Remove feed pipe.
5. Slacken three securing screws
6. Check drive, replace if worn or
7. Replace pump, re-assemble in

PUMP
DRIVE

must be replaced

and remove pump.

damaged.
reverse order.

NOTE: 499 KB ONLY

FIG. 26 A
1. SOFT START SOLENOID
2. RESTRICTOR DISC

Fig. 26

DESN 511995

20

Fig. 26A

DESN 511995

Replacement of parts (Electrical controls)

ELECTRICAL COMPONENT
ACCESS

BEFORE REMOVING SERVICE ACCESS COVERS

ENSURE THAT ALL ELECTRICAL SUPPLIES TO THE
APPLIANCE HAVE BEEN TURNED OFF (SWITCH OFF
AND REMOVE PLUG).

SEE FIG. 27
1.
2.
3.
4.

Remove the controls door and place in a safe position.

Remove both thermostat control knobs.
Remove the 2 cover panel fixing screws.
Remove cover panel. It will be necessary to
disconnect the push on tags from the selector switch.

Fig. 27

DESN 511586 B

Fig. 28

DESN 511587 B

SEE FIG. 28
5. Remove the four control panel fixing screws.
6. Tilt the chassis forwards from the top and lift out. To
fully access the rear of the control chassis, the
thermostat capillaries should be removed from their
pockets.

21

Replacement of parts (Electrical controls)

Fig. 29

DESN 513150
22

Replacement of parts (Electrical controls)

TO FIT NEW BOILER CONTROL

THERMOSTAT

SEE FIG. 30

Follow
instructions
in
section
COMPONENT ACCESS, Steps 1 to 6.

ELECTRICAL

1. Undo the two screws on the front of the chassis which

hold the thermostat in place.
2. Remove the two push on connectors from back of
thermostat.
3. Replace thermostat. Take care to push thermostat
phial correctly into the pocket provided. The
thermostat should be mounted with tag P at the right
hand side.
4. Re-connect push on connector wires . The RED wire
to 1 and YELLOW wire to P.
To complete follow instructions
ASSEMBLE, Steps 1 to 6.

in

section

RE-

Fig. 30

DESN 510546 A

Fig. 31

DESN 510547 A

TO FIT NEW BOILER PUMP

OVERRUN THERMOSTAT
SEE FIG. 31
Follow
instructions
in
section
COMPONENT ACCESS, Steps 1 to 6.

ELECTRICAL

1. Undo the two screws on the front of the chassis which

hold the thermostat in place.
2. Remove the three push on connectors from back of
thermostat.
3. Replace thermostat. The thermostat should be
mounted with tag P at the left hand side.
Take care to push thermostat phial correctly into the
pocket provided.
4. Re-connect push on connector wires. The RED wire
from the pump to P, the other BROWN wire to 2 and
the YELLOW to 1.
To complete follow instructions
ASSEMBLE, Steps 1 to 6.

in

section

RE-

23

Replacement of parts (Electrical controls)

TO FIT NEW COOKER SAFETY
OVERHEAT THERMOSTAT

SEE FIG. 32
Follow
instructions
in
section
COMPONENT ACCESS, Steps 1 to 6.

BLACK

ELECTRICAL
BLACK

1. Undo the two screws on the front of the chassis which

holds the thermostat in place.
2. Remove the two push on connectors from the back of
the thermostat. Open oven door to access the
thermostat phial which passes into the oven at top LH
corner.
3. Remove LH side plate, slacken screw where the phial
passes through RH side and rotate. Slacken screw
front phial mounting bracket rotate. (See Fig. 33).
4. Replace thermostat, thermostat phial should be
repositioned in the same position as removed.
To complete follow instructions
ASSEMBLE, Steps 1 to 6.

in

section

Fig. 32

RE-

24

DESN 512493

Replacement of parts (Electrical controls)

TO FIT NEW BOILER SAFETY

OVERHEAT THERMOSTAT

SEE FIG. 33

Follow
instructions
in
section
COMPONENT ACCESS, Steps 1 to 6.

ELECTRICAL

1. Undo the central hexagon nut on the front of the

chassis which holds the thermostat in place.
2. Remove the push on connectors from back of
thermostat.
3. Replace thermostat. Take care to push thermostat
phial correctly into the pocket provided.
4. Re-connect push on connector wires, as Fig. 33.
To complete follow the instructions in section REASSEMBLE, Steps 1 to 6.
Fig. 33

DESN 516734

TO FIT NEW OVEN CONTROL

THERMOSTAT
SEE FIG. 34
Follow
instructions
in
section
COMPONENT ACCESS, Steps 1 to 6.

ELECTRICAL

1. Undo the two screws on the front of the chassis which

holds the thermostat in place.
2. Remove the 2 push on connectors from back of
thermostat.
3. Open roasting oven door to access the thermostat
phial and capillary which pass into the oven at the top
left hand corner.
4. Remove LH side plate. Slacken the screw where the
phial passes through the roasting oven side and rotate
the cover plate to open up the access hole. Slacken
screw front phial, mounting bracket and rotate.
5. Replace thermostat. The thermostat should be
mounted with tag P at the right hand side. Reposition
the phial in same position as removed.
6. Re-connect push on connector. The VIOLET/BLACK
wire to 1 and BLACK (3) wire to P, See Fig. 34A.

Fig. 34

ENSURE PHIALS DO NOT MAKE

CONTACT WITH OVEN SIDES

DESN 515639

BLACK

NOTE: Ensure phials do not make contact with oven

sides.
To complete follow instructions
ASSEMBLE, Steps 1 to 6.

in

section

RE-

VIOLET
25

Fig. 34A

DESN 510546 A

Replacement of parts (Electrical controls)

TO FIT NEW PROGRAMMER
SEE FIG. 35
Follow instructions in section ELECTRICAL COMPONENT
ACCESS, Steps 1 to 4.
1. Slacken two screws at bottom of programmer.
2. Pull the bottom of the programmer forward and lift..
3. Replace with new programmer. Clip onto the hinges at
the top. Press bottom into place. Tighten two securing
screws.
To complete follow instructions in section RE-ASSEMBLE,
Steps 3 to 6.

Fig. 35

DESN 511602 A

Fig. 36

DESN 510553 A

TO FIT NEW SELECTOR SWITCH

SEE FIG. 36
Follow instructions in section ELECTRICAL COMPONENT
ACCESS, Steps 1 to 4.
1. To remove switch from the cover panel press the two
toggles at the top and bottom of switch, push switch
through panel.
2. Push replacement switch into aperture and click into
place. The switch should be fitted with terminal 1 at the
top.
To complete follow instructions in section RE-ASSEMBLE,
Steps 3 to 6.

26

Replacement of parts (Electrical controls)

RE-ASSEMBLE
1. Locate thermostat phials into boiler pocket.
2. Locate the base of the control chassis into the bottom
of the door way aperture, tilt the chassis backwards
into position and secure with the four screws.
3. Thread the two wires for the selector switch through
the aperture and connect them onto the rear of the
selector switch fitted in the outer panel. Connect the
ORANGE wire on 1 and the PURPLE wire on 2.
4. Refix the outer panel in position and secure with the 2
screws.
5. Replace the thermostat knobs.
6. Replace the controls door.

Fig. 37

27

DESN 511989

Replacement of parts (Vent fan)

VENT FAN
BEFORE REMOVING SERVICE ACCESS COVERS
ENSURE THAT ALL ELECTRICAL SUPPLIES TO THE
APPLIANCE HAVE BEEN TURNED OFF (SWITCH OFF
AND REMOVE PLUG).
SEE FIG. 38
1.
2.
3.
4.
5.
6.
7.

Remove (2) fan cover securing screws, remove cover.

Disconnect green/yellow lead from earth post.
Disconnect blue and brown leads from terminal block.
Break fan duct connection, remove fan assembly.
Remove (2) venturi securing screws.
Remove fan venturi assembly and gasket from fan.
Fit new fan, re-assemble in reverse order.

Fig. 38

DESN 511261

Fig. 39

DESN 510553 A

VENT FAN SWITCH

SEE FIG. 39
1. Remove (2) fan cover securing screws, remove cover.
2. Disconnect push on leads.
3. To remove switch of the cover panel press the two
toggles, at top and bottom of switch, push switch,
through panel.
4. Push replacement switch into aperture and click into
place. The switch should be fitted with terminal 1 at
the top.
5. Re-assemble in reverse order
28

Electrical Controls

PUMP OVERRUN
FACILITY

BOILER

When the programmer switches off the BOILER channel

then the water circulating pump will be switched off. If
during the period shortly after this the residual heat in the
appliance causes the water temperature in the boiler to
rise above 65C then the pump overrun thermostat will
change over. This will switch on the circulating pump.

OVERHEAT SAFETY
THERMOSTATS

This thermostat is a safety cut-out device which is

intended to operate if the other controls fail. This control
will lock-out and switches everything off except for the
programmer clock and the Pump Overrun facility.
This thermostat has to be manually reset once the
temperature has cooled down.
COOKER
This thermostat is a safety cut-out device which operates
if the oven control thermostat fails.
This thermostat automatically
temperature has cooled down.

29

resets

once

the

Electrical Controls
CONTROL CIRCUIT-EXTERNAL

TERMINAL STRIP CONNECTIONS

OVEN VENT FAN

N
SW/L BOILER

SPARE NEUTRAL TERMINAL

SWITCH LIVE TO OPERATE BOILER FROM ROOM STAT
OR CYLINDER STAT VIA ZONE VALVES IF FITTED

HTG ON

TO ROOM STAT/ZONE VALVE(S) ETC ( IF FITTED)

H/W OFF

FROST STAT (SEE NOTE BELOW)

H/W ON

TO CYLINDER STAT/ZONE VALVE(S) ETC (IF FITTED).

PN NEUTRAL

PUMP SUPPLY (THE CIRCULATING PUMP MUST BE

CONNECTED DIRECTLY TO THIS SUPPLY)

PL LIVE

PUMP SUPPLY (THE CIRCULATING PUMP MUST BE

CONNECTED DIRECTLY TO THIS SUPPLY)

L LIVE
N NEUTRAL

3 AMP PERMANENT SUPPLY

E EARTH
NOTE:
If no Hot Water System Controls are used a link MUST be fitted between H/W ON and SW/L BOILER.
If no Central Heating System Controls are used a link MUST be fitted between HTG ON and SW/L BOILER.
If a Frost Thermostat is fitted it MUST be connected to SW/L BOILER and H/W OFF.

30

Electrical Controls
CONTROL CIRCUIT-BOILER

L1

Fig. 40

31

Electrical Controls
CONTROL CIRCUIT-COOKER

L2

L2

Fig. 41

32

Fault Finding

WIRING DIAGRAM APPLIANCE 440/460/480/499KB

Fig. 42

33

Fault Finding
BURNER DOES NOT START
Burners
Check that the burners have not gone to lock-out.
Causes of lock-out can be:l
l
l
l
l
l
l
l

No ignition, ignition electrode incorrectly positioned, insulation cracked, spark generator fault.
No oil supply.
Poor combustion.
Photo electric cell incorrectly positioned, cracked or needs cleaning.
Live and Neutral connections reversed.
Faulty control box.
Faulty fire valve.
Faulty relays.

REFER TO FLOW DIAGRAM FOR ELIMINATION PROCEDURE.

General
You can carry out some checks on the controls before you need to access the controls compartment behind the control
door.
If only one of the burners is not running then the fault must be after the safety overheat thermostat.
Conversely if both burners are affected then the fault lies before the programmer connections.
For access to individual controls refer to section Replacement Parts and for wiring continuity checks refer to Figs. 40, 41
and 42 for detailed and schematic wiring diagrams.
To check out the electrical wiring at the burners you will first have to access the burner chamber. Use the following
procedure:1.
2.
3.
4.

Isolate the electrical power supply.

Open up the bottom burner access door. Remove door and put in a safe place.
Unscrew the 4 screws holding the inner panel in place and remove panel.
Unscrew the 3 screws holding the louvered plinth in place and remove plinth.

The external mains connections are made to a terminal block situated in the front left-hand corner of the burner chamber.
Re-connect the electrical supply and check that there is 230V power supply available cross the mains input connection L
& N on the terminal block, if not then check connecting leads, fuses and whether power is available at mains plug.
If power is available across L & N then check to see whether the overheat cut-out switch has cut-out., if it has been reset
by pushing the centre with a small round tool (i.e. a pencil). Check for continuity across the cooker overheat thermostat.

34

Fault Finding

Cooker Burner (Control Box Type - DKO 970)

Information system

The information system communicates with the outside world using a LED (the used Flash-Code is similar to the Morse
Code). The messages are optically transmitted by flashing appropriately a LED. Using an (optional) additional terminal the
messages can be recorded and displayed in easily readable form.

Programming sequence display

The built-in microprocessor controls not only the programming sequence but the information system too. The individual
phases of the programming sequence are displayed as Flash-Code.
The following messages can be distinguished:-

Fig. 43

35

Fault Finding

Cooker Burner (Control Box Type - DKO 970)

In case of failure the LED is permanently illuminated. Every 10 seconds the illumination is interrupted by a flash code which
indicates the cause of the error. Therefore the following sequence is performed which is repeated as long as the unit is
not reset.
Sequence:

Stray Light Monitoring

The stray light check is performed at the end of the pre-purge timer for the duration as mentioned in the table of timings.
Low-voltage protection

at 220 / 240V (110 / 120V) nominal usage

The mains voltage has to be more than 187Veff (94Veff) in order to allow the unit to perform a start-up.
The mains voltage is not only mentioned in the start-up phase but also permanently during operation. If the voltage drops
below <160Veff (80Veff) during start-up or run time the control box goes into lock-out mode. If the voltage rises again, the
control box performs automatically a start-up as soon as the mains voltage is >187Veff (94Veff).

36

Cooker Burner (Control Box Type DKO 970N) - Information system

Fault Finding

The information system is microprocessor based and reports on all aspects of burner control box operation and flame
supervision. It informs continuously about the actual programming sequence the unit is just performing. Besides monitoring
of the programming sequence it also allows to identify errors during start-up of operation without any additional testing
devices. The automatically performed diagnoses is a valuable tool which facilitates service/maintenance work and
therefore saves costs. The analyses of the error cause can be done directly on stage or if not possible afterwards at the
lockout reason is stored in a non-volatile lock out mode memory.
The information system communicates with the outside world using a LED (the used Flash-Code is similar to the MorseCode). The messages are optically transmitted by flashing apprioriately a LED. Using an (optional) additional terminal the
messages can be recorded and displayed in easy readable form.

Programming sequence display

The built-in microprocessor controls not only the programming sequence but the information system too. The individual
phases of the programming sequence are displayed as Flash-Code.
The following messages can be distinguished:

Fig. 44

DESN 516837

Lock-out diagnoses

In case of failure the LED is permanently illuminated. Every 10 seconds the illumination is interrupted by a flash code,
which indicates the cause of the error. Therefore the following sequence is performed which is repeated as long as the
unit is not reset.
Sequence:

Blinking Codes: See Fig. 44A

Stray Light Monitoring
The stray light check is performed at the end of the pre-purge time for the duration as mentioned in the table of timings
Table of timings (sec.)
Model

Pre-purge and
pre-ignition time
tv1

stray light
monitoring
tf

safety time
ts

post-ignition
time after v1
tn

delay time to V2
DKO 972-N-only
tv2

05

15

20

37

Fault Finding

Fig. 44A

38

DESN 516838

Fault Finding

39

Fault Finding

40

Fault Finding

41

Fault Finding

42

Fault Finding

43

For further advice or information contact

your local distributor/stockist

With AGA Rangemasters policy of continuous

product improvement, the Company reserves the
right to change specifications and make
modifications to the appliance described at any
time.

Manufactured by
AGA Rangemaster
Station Road
Ketley Telford
Shropshire TF1 5AQ
England
www.rayburn-web.co.uk
www.agacookshop.co.uk

44